Automated method for transferring lenses in a hydrated state from molds to receivers

Abstract

To break up high surface tension forces between an amorphous lens mold and a hydrated lens, a precise x-and-y-coordinate motion tangential to the lens surface is used in combination with a z-coordinate motion using the vacuum of a lens pick and place robot. The sequence of motions permits the transfer of lenses in an automated fashion from the molding step to a subsequent process in a robust and accurate manner, thereby minimizing lens-handling defects.

1 . A method for removing a hydrated contact lens from a mold, comprising the steps of: 
 moving the lens in a pattern tangential to the surface of the lens still adhering to the mold; and    applying sufficient force on the lens normal to and away from the mold to separate the lens from the mold.    
     
     
         2 . The method of  claim 1 , wherein the step of moving the lens in a pattern tangential to the surface of the lens still adhering to the mold further comprises the steps of: 
 moving the lens in a first linear direction tangential to the surface of the lens;    moving the lens in a second linear direction tangential to the surface of the lens and at a large angle to the first linear direction; and    rotating the lens around an axis normal to the lens surface.    
     
     
         3 . The method of  claim 1 , wherein the step of moving the lens in a pattern tangential to the surface of the lens still adhering to the mold further comprises the steps of: 
 moving the lens in a first linear direction tangential to the surface of the lens; and    moving the lens in a second linear direction tangential to the surface of the lens and at a large angle to the first linear direction.    
     
     
         4 . The method of  claim 1 , wherein the step of moving the lens in a pattern tangential to the surface of the lens still adhering to the mold further comprises the step of moving the lens in a linear direction tangential to the surface of the lens.  
     
     
         5 . The method of  claim 1 , wherein the step of moving the lens in a pattern tangential to the surface of the lens still adhering to the mold further comprises the steps of: 
 moving the lens in a series of distinct linear directions tangential to the surface of the lens; and    rotating the lens around an axis normal to the lens surface.    
     
     
         6 . The method of  claim 1 , wherein the step of moving the lens in a pattern tangential to the surface of the lens still adhering to the mold further comprises the steps of: 
 moving the lens in a series of changing and recurring linear directions tangential to the surface of the lens; and    rotating the lens around an axis normal to the lens surface.    
     
     
         7 . The method of  claim 1 , wherein the step of moving the lens in a pattern tangential to the surface of the lens still adhering to the mold further comprises the step of rotating the lens around an axis normal to the lens surface.  
     
     
         8 . The method of  claim 1 , wherein the step of moving the lens in a pattern tangential to the surface of the lens still adhering to the mold further comprises the steps of: 
 rotating the lens around an axis normal to the lens surface; and    moving the lens in a series of distinct linear directions tangential to the surface of the lens.    
     
     
         9 . The method of  claim 1 , wherein the step of moving the lens in a pattern tangential to the surface of the lens still adhering to the mold further comprises the steps of: 
 rotating the lens around an axis normal to the lens surface; and    moving the lens in a series of changing and recurring linear directions tangential to the surface of the lens.    
     
     
         10 . The method of  claim 1 , wherein the step of moving the lens in a pattern tangential to the surface of the lens still adhering to the mold further comprises the steps of: 
 rotating the lens around an axis normal to the lens surface while moving the lens in a series of distinct linear directions tangential to the surface of the lens.    
     
     
         11 . The method of  claim 1 , wherein the step of moving the lens in a pattern tangential to the surface of the lens still adhering to the mold further comprises the steps of: 
 rotating the lens around an axis normal to the lens surface while moving the lens in a series of changing and recurring linear directions tangential to the surface of the lens.    
     
     
         12 . The method of  claim 1 , wherein the step of applying sufficient force on the lens normal to and away from the mold to separate the lens from the mold comprises applying sufficient vacuum on the lens normal to and away from the mold to separate the lens from the mold.  
     
     
         13 . A method for removing a hydrated contact lens from a mold, comprising the steps of: 
 moving the lens in a pattern tangential to the surface of the lens still adhering to the mold while applying sufficient force on the lens normal to and away from the mold to separate the lens from the mold.    
     
     
         14 . The method of  claim 13 , wherein the step of moving the lens in a pattern tangential to the surface of the lens still adhering to the mold while applying sufficient force on the lens normal to and away from the mold to separate the lens from the mold comprises moving the lens in a pattern tangential to the surface of the lens still adhering to the mold while applying sufficient vacuum on the lens normal to and away from the mold to separate the lens from the mold.  
     
     
         15 . The method of  claim 14 , wherein the step of moving the lens in a pattern tangential to the surface of the lens still adhering to the mold while applying sufficient vacuum on the lens normal to and away from the mold to separate the lens from the mold further comprises the steps of: 
 moving the lens in a first linear direction tangential to the surface of the lens;    moving the lens in a second linear direction tangential to the surface of the lens and at a large angle to the first linear direction; and    rotating the lens around an axis normal to the lens surface.    
     
     
         16 . The method of  claim 14 , wherein the step of moving the lens in a pattern tangential to the surface of the lens still adhering to the mold while applying sufficient vacuum on the lens normal to and away from the mold to separate the lens from the mold further comprises the steps of: 
 moving the lens in a first linear direction tangential to the surface of the lens; and    moving the lens in a second linear direction tangential to the surface of the lens and at a large angle to the first linear direction.    
     
     
         17 . The method of  claim 14 , wherein the step of moving the lens in a pattern tangential to the surface of the lens still adhering to the mold while applying sufficient vacuum on the lens normal to and away from the mold to separate the lens from the mold further comprises the step of moving the lens in a linear direction tangential to the surface of the lens.  
     
     
         18 . The method of  claim 14 , wherein the step of moving the lens in a pattern tangential to the surface of the lens still adhering to the mold while applying sufficient vacuum on the lens normal to and away from the mold to separate the lens from the mold further comprises the steps of: 
 moving the lens in a series of distinct linear directions tangential to the surface of the lens; and    rotating the lens around an axis normal to the lens surface.    
     
     
         19 . The method of  claim 14 , wherein the step of moving the lens in a pattern tangential to the surface of the lens still adhering to the mold while applying sufficient vacuum on the lens normal to and away from the mold to separate the lens from the mold further comprises the steps of: 
 moving the lens in a series of changing and recurring linear directions tangential to the surface of the lens; and    rotating the lens around an axis normal to the lens surface.    
     
     
         20 . The method of  claim 14 , wherein the step of moving the lens in a pattern tangential to the surface of the lens still adhering to the mold while applying sufficient vacuum on the lens normal to and away from the mold to separate the lens from the mold further comprises the step of rotating the lens around an axis normal to the lens surface.  
     
     
         21 . The method of  claim 14 , wherein the step of moving the lens in a pattern tangential to the surface of the lens still adhering to the mold while applying sufficient vacuum on the lens normal to and away from the mold to separate the lens from the mold further comprises the steps of: 
 rotating the lens around an axis normal to the lens surface; and    moving the lens in a series of distinct linear directions tangential to the surface of the lens.    
     
     
         22 . The method of  claim 14 , wherein the step of moving the lens in a pattern tangential to the surface of the lens still adhering to the mold while applying sufficient vacuum on the lens normal to and away from the mold to separate the lens from the mold further comprises the steps of: 
 rotating the lens around an axis normal to the lens surface; and    moving the lens in a series of changing and recurring linear directions tangential to the surface of the lens.    
     
     
         23 . The method of  claim 14 , wherein the step of moving the lens in a pattern tangential to the surface of the lens still adhering to the mold while applying sufficient vacuum on the lens normal to and away from the mold to separate the lens from the mold further comprises the steps of: 
 rotating the lens around an axis normal to the lens surface while moving the lens in a series of distinct linear directions tangential to the surface of the lens.    
     
     
         24 . The method of  claim 14 , wherein the step of moving the lens in a pattern tangential to the surface of the lens still adhering to the mold while applying sufficient vacuum on the lens normal to and away from the mold to separate the lens from the mold further comprises the steps of: 
 rotating the lens around an axis normal to the lens surface while moving the lens in a series of changing and recurring linear directions tangential to the surface of the lens.    
     
     
         25 . A method for removing a hydrated contact lens from a mold, comprising the steps of: 
 applying sufficient vacuum to an exposed face of the lens to hold the lens securely;    moving the lens in a pattern tangential to the surface of the lens still adhering to the mold; and    applying sufficient force on the lens normal to and away from the mold to separate the lens from the mold.    
     
     
         26 . The method of  claim 25 , wherein the step of moving the lens in a pattern tangential to the surface of the lens still adhering to the mold further comprises the steps of: 
 moving the lens in a first linear direction tangential to the surface of the lens;    moving the lens in a second linear direction tangential to the surface of the lens and at a large angle to the first linear direction; and    rotating the lens around an axis normal to the lens surface.    
     
     
         27 . The method of  claim 25 , wherein the step of moving the lens in a pattern tangential to the surface of the lens still adhering to the mold further comprises the steps of: 
 moving the lens in a first linear direction tangential to the surface of the lens; and    moving the lens in a second linear direction tangential to the surface of the lens and at a large angle to the first linear direction.    
     
     
         28 . The method of  claim 25 , wherein the step of moving the lens in a pattern tangential to the surface of the lens still adhering to the mold further comprises the step of moving the lens in a linear direction tangential to the surface of the lens.  
     
     
         29 . The method of  claim 25 , wherein the step of moving the lens in a pattern tangential to the surface of the lens still adhering to the mold further comprises the steps of: 
 moving the lens in a series of distinct linear directions tangential to the surface of the lens; and    rotating the lens around an axis normal to the lens surface.    
     
     
         30 . The method of  claim 25 , wherein the step of moving the lens in a pattern tangential to the surface of the lens still adhering to the mold further comprises the steps of: 
 moving the lens in a series of changing and recurring linear directions tangential to the surface of the lens; and    rotating the lens around an axis normal to the lens surface.    
     
     
         31 . The method of  claim 25 , wherein the step of moving the lens in a pattern tangential to the surface of the lens still adhering to the mold further comprises the step of rotating the lens around an axis normal to the lens surface.  
     
     
         32 . The method of  claim 25 , wherein the step of moving the lens in a pattern tangential to the surface of the lens still adhering to the mold further comprises the steps of: 
 rotating the lens around an axis normal to the lens surface; and    moving the lens in a series of distinct linear directions tangential to the surface of the lens.    
     
     
         33 . The method of  claim 25 , wherein the step of moving the lens in a pattern tangential to the surface of the lens still adhering to the mold further comprises the steps of: 
 rotating the lens around an axis normal to the lens surface; and    moving the lens in a series of changing and recurring linear directions tangential to the surface of the lens.    
     
     
         34 . The method of  claim 25 , wherein the step of moving the lens in a pattern tangential to the surface of the lens still adhering to the mold further comprises the steps of: 
 rotating the lens around an axis normal to the lens surface while moving the lens in a series of distinct linear directions tangential to the surface of the lens.    
     
     
         35 . The method of  claim 25 , wherein the step of moving the lens in a pattern tangential to the surface of the lens still adhering to the mold further comprises the steps of: 
 rotating the lens around an axis normal to the lens surface while moving the lens in a series of changing and recurring linear directions tangential to the surface of the lens.    
     
     
         36 . The method of  claim 25 , wherein the step of applying sufficient force on the lens normal to and away from the mold to separate the lens from the mold comprises applying sufficient vacuum on the lens normal to and away from the mold to separate the lens from the mold.  
     
     
         37 . A method for removing a hydrated contact lens from a mold, comprising the steps of: 
 exposing one face of the lens by removing one or more mold sections;    positioning a vacuum instrument over the exposed face of the lens;    applying sufficient vacuum to the exposed face of the lens to hold the lens securely;    moving the lens in a pattern tangential to the surface of the lens still adhering to the mold; and    applying sufficient force on the lens normal to and away from the mold to separate the lens from the mold.    
     
     
         38 . The method of  claim 37 , wherein the step of moving the lens in a pattern tangential to the surface of the lens still adhering to the mold further comprises the steps of: 
 moving the lens in a first linear direction tangential to the surface of the lens;    moving the lens in a second linear direction tangential to the surface of the lens and at a large angle to the first linear direction; and    rotating the lens around an axis normal to the lens surface.    
     
     
         39 . The method of  claim 37 , wherein the step of moving the lens in a pattern tangential to the surface of the lens still adhering to the mold further comprises the steps of: 
 moving the lens in a first linear direction tangential to the surface of the lens; and    moving the lens in a second linear direction tangential to the surface of the lens and at a large angle to the first linear direction.    
     
     
         40 . The method of  claim 37 , wherein the step of moving the lens in a pattern tangential to the surface of the lens still adhering to the mold further comprises the step of moving the lens in a linear direction tangential to the surface of the lens.  
     
     
         41 . The method of  claim 37 , wherein the step of moving the lens in a pattern tangential to the surface of the lens still adhering to the mold further comprises the steps of: 
 moving the lens in a series of distinct linear directions tangential to the surface of the lens; and    rotating the lens around an axis normal to the lens surface.    
     
     
         42 . The method of  claim 37 , wherein the step of moving the lens in a pattern tangential to the surface of the lens still adhering to the mold further comprises the steps of: 
 moving the lens in a series of changing and recurring linear directions tangential to the surface of the lens; and    rotating the lens around an axis normal to the lens surface.    
     
     
         43 . The method of  claim 37 , wherein the step of moving the lens in a pattern tangential to the surface of the lens still adhering to the mold further comprises the step of rotating the lens around an axis normal to the lens surface.  
     
     
         44 . The method of  claim 37 , wherein the step of moving the lens in a pattern tangential to the surface of the lens still adhering to the mold further comprises the steps of: 
 rotating the lens around an axis normal to the lens surface; and    moving the lens in a series of distinct linear directions tangential to the surface of the lens.    
     
     
         45 . The method of  claim 37 , wherein the step of moving the lens in a pattern tangential to the surface of the lens still adhering to the mold further comprises the steps of: 
 rotating the lens around an axis normal to the lens surface; and    moving the lens in a series of changing and recurring linear directions tangential to the surface of the lens.    
     
     
         46 . The method of  claim 37 , wherein the step of moving the lens in a pattern tangential to the surface of the lens still adhering to the mold further comprises the steps of: 
 rotating the lens around an axis normal to the lens surface while moving the lens in a series of distinct linear directions tangential to the surface of the lens.    
     
     
         47 . The method of  claim 37 , wherein the step of moving the lens in a pattern tangential to the surface of the lens still adhering to the mold further comprises the steps of: 
 rotating the lens around an axis normal to the lens surface while moving the lens in a series of changing and recurring linear directions tangential to the surface of the lens.    
     
     
         48 . The method of  claim 37 , wherein the step of applying sufficient force on the lens normal to and away from the mold to separate the lens from the mold comprises applying sufficient vacuum on the lens normal to and away from the mold to separate the lens from the mold.